Tube Bending Digital Twin for Real-Time State Prediction
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Solution Overview
Problem
Traditional tube bending methods lack intelligence and real-time monitoring, leading to inefficiencies and accuracy issues in producing high-quality tube fittings, as they rely on manual testing and off-line measurements.
Innovation Solution
A digital twin system for real-time monitoring and prediction of tube bending processes, utilizing a data acquisition system, data processing system, and twin model system to monitor and predict the state of tube bending devices and fittings, incorporating sensors for data collection, Kalman filtering, and spatio-temporal fusion transformation based on multi-task learning for accurate predictions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manual testing and off-line measurement methods are used, then the tube bending process can be completed, but the efficiency is low and accuracy cannot be guaranteed
Solution Approach 1:
The patent replaces manual testing and off-line measurement methods with an automated digital twin system that uses sensors, data acquisition devices, and computational models to monitor and predict tube bending processes in real-time, thereby improving both precision and efficiency simultaneously
Solution Approach 2:
The patent creates a digital twin (virtual copy) of the physical tube bending system that replicates the bending process in virtual space, allowing for real-time monitoring and prediction without interfering with the actual production process, thus improving both quality and efficiency
2Extent of automation
If traditional open-loop control method is used, then the tube bending device can operate, but real-time monitoring and intelligence are lacking
Solution Approach 1:
The patent implements a closed-loop control system where sensors continuously collect data from the tube bending device, the digital twin processes this information, and the results feed back to adjust the bending process in real-time, eliminating the information loss inherent in open-loop systems and enabling intelligent automation
Solution Approach 2:
The patent introduces a digital twin as an intermediary between the physical tube bending device and the control system, which acts as a virtual model that processes sensor data and provides predictions, thereby enabling real-time monitoring and intelligence without direct interference in the physical process
3Extent of automation
If digital twin system is implemented for real-time monitoring, then intelligence and prediction capability are improved, but system complexity increases
Solution Approach 1:
The patent designs the digital twin system to perform multiple functions (monitoring, prediction, optimization, and control) through a single integrated platform, reducing the need for separate systems and thereby managing complexity while enhancing automation and intelligence
Data Source
AI summary
Disclosed is a method and digital twin system for real-time monitoring and prediction of tube bending process state. By mounting gyroscopes and force sensors in tube bending devices, bending dies, pressing dies and other dies, the data of position, speed and acceleration of each die, as well as pressure and friction between each die and tube fittings can be acquired in real time. In the present disclosure, the acquisition of bending state of the tube bending device die and the tube fitting can be realized, and the real-time monitoring and prediction of bending process state can be realized, thereby improving the accuracy of tube bending device and the quality of tube bending.